Virtual-Box/.claude/file-history/138484f6-474d-4740-8791-b8f49f53e200/d085fa8863fff790@v2

// ============================================================
// ANOMALY DETECTOR
// Detects production anomalies in real-time
// ============================================================

const cycle = msg.cycle || {};
const kpis = msg.kpis || {};
const activeOrder = global.get("activeWorkOrder") || {};

// Must have active work order to detect anomalies
if (!activeOrder.id) {
    return null;
}

const theoreticalCycleTime = Number(activeOrder.cycleTime) || 0;
const now = Date.now();

// Get or initialize anomaly tracking state
let anomalyState = global.get("anomalyState") || {
    lastCycleTime: now,
    activeStoppageEvent: null
};

const detectedAnomalies = [];

// ============================================================
// 1. SLOW CYCLE DETECTION
// Trigger: Actual cycle time > 1.5x theoretical
// ============================================================
if (theoreticalCycleTime > 0) {
    const timeSinceLastCycle = now - anomalyState.lastCycleTime;
    const actualCycleTime = timeSinceLastCycle / 1000; // Convert to seconds
    const threshold = theoreticalCycleTime * 1.5;

    if (actualCycleTime > threshold && anomalyState.lastCycleTime > 0) {
        const deltaPercent = ((actualCycleTime - theoreticalCycleTime) / theoreticalCycleTime) * 100;

        // Determine severity
        let severity = 'warning';
        if (actualCycleTime > theoreticalCycleTime * 2.0) {
            severity = 'critical';  // 100%+ slower
        }

        detectedAnomalies.push({
            anomaly_type: 'slow-cycle',
            severity: severity,
            title: `Slow Cycle Detected`,
            description: `Cycle took ${actualCycleTime.toFixed(1)}s (${deltaPercent.toFixed(0)}% slower than expected ${theoreticalCycleTime}s)`,
            data: {
                actual_cycle_time: actualCycleTime,
                theoretical_cycle_time: theoreticalCycleTime,
                delta_percent: Math.round(deltaPercent),
                threshold_multiplier: actualCycleTime / theoreticalCycleTime
            },
            kpi_snapshot: {
                oee: kpis.oee || 0,
                availability: kpis.availability || 0,
                performance: kpis.performance || 0,
                quality: kpis.quality || 0
            },
            work_order_id: activeOrder.id,
            cycle_count: cycle.cycles || 0,
            timestamp: now
        });

        node.warn(`[ANOMALY] Slow cycle: ${actualCycleTime.toFixed(1)}s (expected ${theoreticalCycleTime}s)`);
    }
}

// ============================================================
// 2. PRODUCTION STOPPAGE DETECTION
// Trigger: No cycle in > 3x theoretical cycle time
// ============================================================
if (theoreticalCycleTime > 0) {
    const timeSinceLastCycle = now - anomalyState.lastCycleTime;
    const stoppageThreshold = theoreticalCycleTime * 3 * 1000; // Convert to ms

    // If we have an active stoppage event and a new cycle arrived, resolve it
    if (anomalyState.activeStoppageEvent) {
        // Cycle resumed - mark stoppage as resolved
        anomalyState.activeStoppageEvent.resolved_at = now;
        anomalyState.activeStoppageEvent.auto_resolved = true;
        anomalyState.activeStoppageEvent.status = 'resolved';

        const stoppageDuration = (now - anomalyState.activeStoppageEvent.timestamp) / 1000;
        node.warn(`[ANOMALY] Production resumed after ${stoppageDuration.toFixed(0)}s stoppage`);

        // Send resolution event
        detectedAnomalies.push(anomalyState.activeStoppageEvent);
        anomalyState.activeStoppageEvent = null;
    }

    // Check if production has stopped (only if no active stoppage event)
    if (!anomalyState.activeStoppageEvent && timeSinceLastCycle > stoppageThreshold && anomalyState.lastCycleTime > 0) {
        const stoppageSeconds = timeSinceLastCycle / 1000;

        // Determine severity
        let severity = 'warning';
        if (stoppageSeconds > theoreticalCycleTime * 5) {
            severity = 'critical';  // Stopped for 5x+ theoretical time
        }

        const stoppageEvent = {
            anomaly_type: 'production-stopped',
            severity: severity,
            title: `Production Stoppage`,
            description: `No cycles detected for ${stoppageSeconds.toFixed(0)}s (expected cycle every ${theoreticalCycleTime}s)`,
            data: {
                stoppage_duration_seconds: Math.round(stoppageSeconds),
                theoretical_cycle_time: theoreticalCycleTime,
                last_cycle_timestamp: anomalyState.lastCycleTime,
                threshold_multiplier: stoppageSeconds / theoreticalCycleTime
            },
            kpi_snapshot: {
                oee: kpis.oee || 0,
                availability: kpis.availability || 0,
                performance: kpis.performance || 0,
                quality: kpis.quality || 0
            },
            work_order_id: activeOrder.id,
            cycle_count: cycle.cycles || 0,
            timestamp: now,
            status: 'active'
        };

        detectedAnomalies.push(stoppageEvent);
        anomalyState.activeStoppageEvent = stoppageEvent;

        node.warn(`[ANOMALY] Production stopped: ${stoppageSeconds.toFixed(0)}s since last cycle`);
    }
}

// Update last cycle time for next iteration
anomalyState.lastCycleTime = now;
global.set("anomalyState", anomalyState);

// ============================================================
// OUTPUT
// ============================================================
if (detectedAnomalies.length > 0) {
    node.warn(`[ANOMALY DETECTOR] Detected ${detectedAnomalies.length} anomaly/ies`);

    return {
        topic: "anomaly-detected",
        payload: detectedAnomalies,
        originalMsg: msg  // Pass through original message for other flows
    };
}

return null;  // No anomalies detected